Smart high-speed machining simulator (SHSMSimul)

High speed machining (HSM) induces a complex tool path interpolation to guarantee high speed smooth motion and the machined part quality. Moreover, during complex part machining, an interaction can appear between the control law behavior and the programmed interpolated path which generates disturbances and non-qualities in the machining operation. Thus, there is an issue to develop simulator software of machine-tool Numerical Controller (NC) to grantee the final quality to simulate the machining quality operation and reduce machining trials thanks to high-fidelity simulation before launching a mass-production machining parts. The development of Multiphysics simulation is an open issue, both on industrial and university scale. Until now, no CNC simulation software is available that is able to simulate a high-speed machining operation of a complex part (taking into account the effect of the interaction phenomenon between tool path, interpolation, control law and machine-tool kinematic on the machining quality). Currently, the choice of computer-aided manufacturing (CAM) parameters is based on the experience feedback of CAM programmers and its estimates of the CNC machine kinematic behavior. In this project, the goal is to develop a numerical simulation environment which allows helping to identify appropriate CAM parameters with regard to an adapted part quality. To do this, we have to develop a simulation software prototype of the machinetool NC and kinematic behavior for free form surface machining. Currently, results of the analytical models developed in the case of 3 and 5 axis HSM of complex parts with contour tolerance programmed showed a good correlation with the experimental validation tests. We have also recorded a 100% enhancement of the axis motion accuracy through the digitization of the optimal smoothing tolerance to be programmed.